3.2l - Multiport Fuel Injection - Engine Code(s): Cala (coupe) Audi A5 I

SAFETY PRECAUTIONS

Observe the following if test and measuring instruments are required during a test drive

To reduce the risk of personal injury and/or damage to the fuel injection and ignition system, always observe the following

Scheme 175

1. For safety reasons, if the battery is not disconnected, then the fuse - located in fuse holder in the instrument panel on the driver side- must be removed from the fuel pump control module -J538- before opening the fuel system, otherwise the fuel pump will be activated by the driver's door contact switch.
2. Individuals with a pacemaker must not stay in the danger area of high voltage systems, for example ignition systems, xenon light.
3. Fuel lines must not be opened when engine is running.
4. Only disconnect and reconnect wires for injection and ignition system, including test leads, when ignition is switched off.
5. If engine is to be cranked at starting RPM without starting (for example for compression testing), disconnect connectors from ignition coils and remove fuse for electric fuel pump.
6. It is possible that the control module will recognize a malfunction and store a DTC during some tests. Therefore after completing all checks and repairs the DTC memory must be checked and if necessary erased.
7. Cleaning the engine should only be performed with ignition switched off.
8. The battery must only be disconnected and connected with the ignition switched off, since the Engine Control Module (ECM) can otherwise be damaged.

CLEAN WORKING CONDITIONS

Even minor contamination can lead to malfunctions in the fuel injection system. Therefore when working on the fuel supply/injection system, pay careful attention to the following rules of cleanliness

1. Before loosening, connections and surrounding areas must be cleaned thoroughly with engine or brake cleaner, and then cleaned area must be dried completely.
2. Plug open lines and connections immediately with appropriate protective caps.
3. Place parts that have been removed on a clean surface and cover them. Use lint-free cloths.
4. Install only clean parts: remove the replacement parts from their packaging just before installing them. Do not use parts that have been stored unpacked (for example in tool boxes etc.).
5. When the system is open: do not work with compressed air. Do not move vehicle unless absolutely necessary.

BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM

High Fuel Pressure, Reducing

Connect vehicle diagnosis, testing & info. system VAS 5051B.

Scheme 176

Start engine and run at idle speed.

Select engine electronics in OBD.

Then select measured values.

Select fuel pressure from the list.

When the engine is at idle, fuel pressure between 30 and 40 bar is displayed.

Pry off the cover -1- on the left of the instrument panel, for example using the trim removal wedge 3409 -arrow-.

Scheme 177

While the engine is idling, remove the fuse -in the fuse holder inside the instrument panel on the driver side- from the fuel pump control module -J538-, refer to the appropriate SYSTEM WIRING DIAGRAMS information.

Check fuel pressure.

1. The fuel pressure decreases rapidly because the mechanical high pressure pump is no longer supplied with fuel from the transfer fuel pump -G6-.

Switch the ignition off as soon as the fuel pressure drops to approximately 8 bar.

Note. The fuel pressure must not drop below 6 bar, because otherwise the engine will shut off (risk of catalytic converter damage).

After reducing fuel pressure, place a clean cloth around the connection and open the high pressure system immediately. Escaping fuel must be absorbed.

Perform the following steps are completing all work

Install the fuse.

Erase the DTC memory and, using guided fault finding, generate the readiness code in the engine control module vehicle diagnosis, testing and information system VAS 5051B.

ON BOARD DIAGNOSTICS (OBD) GENERAL INFORMATION

1. The engine control module is equipped with On Board Diagnostics (OBD). Before repairs such as fault finding, check the DTC memory first. Also the vacuum hoses and connections must be checked (unmetered air).
2. Fuel hoses in engine compartment must only be secured with spring-type clips. The use of clamp or screw type clips is not permissible.
3. For the electric components to work properly, a voltage of at least 11.5 Volts is required.
4. Do not use sealants containing silicone. Particles of silicone drawn into the engine, will not be burnt in the engine and damage the oxygen sensor.
5. The vehicles have a crash fuel shut-off. It reduces the risk of fire in an accident because the fuel pump relay switches the fuel pump off.
6. This setup also makes it easier to start the engine. When the driver-side door is opened, the fuel pump (FP) is activated for 2 seconds so that pressure builds in the fuel system, observe safety measures. Refer to «SAFETY PRECAUTIONS»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe__safety-precautions) .

Scheme 178

1. Heated Oxygen Sensor -G39- Component location, refer to «OXYGEN SENSORS LOCATION, CYLINDER BANK 1 (RIGHT)»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) Location of electrical connector, refer to «CONNECTORS ON THE RIGHT SIDE OF CYLINDER BANK 1»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) Removing and installing, refer to «HEATED OXYGEN SENSOR IN FRONT OF RIGHT CATALYTIC CONVERTER»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe__heated-oxygen-sensor-in-front-of) 55 Nm
2. Exhaust Camshaft Adjustment Valve 1 -N318- 2.5 Nm Replace O-rings Component location, refer to «LOCATION ON THE RIGHT CYLINDER BANK 1»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe)
3. Camshaft Adjustment Valve 1 -N205- 2.5 Nm Replace O-rings Component location, refer to «LOCATION ON THE RIGHT CYLINDER BANK 1»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe)
4. Oxygen Sensor After Three Way Catalytic Converter -G130- Component location, refer to «OXYGEN SENSORS LOCATION, CYLINDER BANK 1 (RIGHT)»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) Connector location, refer to «CONNECTORS ON THE RIGHT SIDE OF CYLINDER BANK 1»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) Removing and installing, refer to «OXYGEN SENSOR BEHIND THREE WAY CATALYTIC CONVERTER»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe__oxygen-sensor-behind-three-way-catalytic) 55 Nm
5. Connectors For the fuel injectors, cylinder bank 1 For the throttle valve control module -J338- For knock sensor 1 -G61- For heated oxygen sensor -G39- For oxygen sensor after three way catalytic converter -G130- Connector locations, refer to «CONNECTORS ON THE RIGHT SIDE OF CYLINDER BANK 1»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe)
6. Throttle Valve Control Module -J338- With EPC throttle drive -G186-, EPC throttle drive angle sensor 1 -G187- and EPC throttle drive angle sensor 2 -G188- After replacement, adapt in guided functions operating mode under adapting throttle valve control module Component location, refer to «COMPONENT LOCATION ON REAR OF INTAKE MANIFOLD»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe)
7. EVAP Canister Purge Regulator Valve 1 -N80
8. Intake Air Temperature Sensor -G42- /Manifold Absolute Pressure Sensor -G71- Component location, refer to «COMPONENT LOCATION ON REAR OF INTAKE MANIFOLD»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe)
9. Fuel Injector, Cylinder Bank 1 Cylinder 3 fuel injector -N32- Component location, refer to «COMPONENT LOCATION VIEW FROM INSIDE FROM THE RIGHT CYLINDER BANK 1»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) Removing and installing, refer to «FUEL INJECTORS»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe__fuel-injectors)
10. Knock Sensor 1 -G61- Component location, refer to «COMPONENT LOCATION VIEW FROM INSIDE FROM THE RIGHT CYLINDER BANK 1»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) Location of electrical connector, refer to «CONNECTORS ON THE RIGHT SIDE OF CYLINDER BANK 1»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) Removing and installing, refer to «KNOCK SENSORS»(ref-520191-S02091926662012123100000)
11. Fuel Injectors, Cylinder Bank 1 Cylinder 1 fuel injector -N30- Cylinder 2 fuel injector -N31- Component location, refer to «COMPONENT LOCATION VIEW FROM INSIDE FROM THE RIGHT CYLINDER BANK 1»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) Removing and installing, refer to «FUEL INJECTORS»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe__fuel-injectors)
12. Intake Manifold Tuning Valve Position Sensor -G513
13. Intake Manifold Tuning Valve -N156- Component location, refer to «COMPONENT LOCATION FRONT ON ENGINE»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe)
14. Actuator for Intake Manifold Change-Over Vacuum diaphragm
15. Engine Coolant Temperature Sensor -G62- Component location, refer to «COMPONENT LOCATION FRONT ON ENGINE»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe)
16. Camshaft Position Sensor -G40- 9 Nm Replace O-rings Component location, refer to «LOCATION ON THE RIGHT CYLINDER BANK 1»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) Removing and installing, refer to «CAMSHAFT POSITION SENSOR»(ref-520191-S36668883822012123100000)
17. Camshaft Adjuster Actuators Cam adjustment actuator 1 -F366- Cam adjustment actuator 2 -F367- Cam adjustment actuator 3 -F368- Cam adjustment actuator 4 -F369- Cam adjustment actuator 5 -F370- Cam adjustment actuator 6 -F371- Component location, refer to «LOCATION ON THE RIGHT CYLINDER BANK 1»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe)
18. High Pressure Pump With low fuel pressure sensor -G410- and fuel metering valve -N290- Component location, refer to «COMPONENT LOCATION ON THE HIGH PRESSURE PUMP»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) Removing and installing, refer to «HIGH PRESSURE PUMP»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe__high-pressure-pump)
19. Ignition Coils, Cylinder Bank 1 Ignition coil 1 with power output stage -N70- Ignition coil 2 with power output stage -N127- Ignition coil 3 with power output stage -N291- Removing and installing, refer to «IGNITION COILS»(ref-520191-S17023316332012123100000)
20. Camshaft Position Sensor 3 -G300- 9 Nm Replace O-rings Component location, refer to «LOCATION ON THE RIGHT CYLINDER BANK 1»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) Removing and installing, refer to «CAMSHAFT POSITION SENSOR»(ref-520191-S36668883822012123100000)
21. Secondary Air Injection Pump Motor -V101- Not installed on all vehicles (EU 5 only) Removing and installing, refer to «Removal and Installation»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008)
22. Intake Air Switch-Over Valve -N335- Not equipped on all vehicles

Scheme 179

1. Left Holder for Connectors For knock sensor 2 -G66- For the fuel injectors, cylinder bank 2 For the fuel pressure sensor -G247- Connector locations, refer to «ELECTRICAL CONNECTORS»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe)
2. Oxygen Sensor 2 after Catalytic Converter -G131- Component location, refer to «OXYGEN SENSORS LOCATION, CYLINDER BANK 2 (LEFT)»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) Location of electrical connector, refer to «OXYGEN SENSOR ELECTRICAL CONNECTORS ON CYLINDER BANK 2 (LEFT)»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) Removing and installing, refer to «OXYGEN SENSOR 2 BEHIND THREE WAY CATALYTIC CONVERTER»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe__oxygen-sensor-2-behind-three-way) 55 Nm
3. Camshaft Adjustment Valve 2 -N208- 2.5 Nm Replace O-rings Component location, refer to «LOCATION ON LEFT CYLINDER BANK 2»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe)
4. Exhaust camshaft adjustment valve 2 -N319- 2.5 Nm Replace O-rings Component location, refer to «LOCATION ON LEFT CYLINDER BANK 2»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe)
5. Engine Control Module -J623- Component location, refer to «LOCATION ENGINE CONTROL MODULE -J623»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) Removing and installing, refer to «ENGINE CONTROL MODULE»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe__engine-control-module)
6. Heated Oxygen Sensor 2 -G108- 55 Nm Component location, refer to «OXYGEN SENSORS LOCATION, CYLINDER BANK 2 (LEFT)»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) Location of electrical connector, refer to «OXYGEN SENSOR ELECTRICAL CONNECTORS ON CYLINDER BANK 2 (LEFT)»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) Removing and installing, refer to «HEATED OXYGEN SENSOR 2»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe__heated-oxygen-sensor-2)
7. Camshaft Position Sensor 4 -G301- 9 Nm Replace O-rings Component location, refer to «LOCATION ON LEFT CYLINDER BANK 2»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) Removing and installing, refer to «CAMSHAFT POSITION SENSOR»(ref-520191-S36668883822012123100000)
8. Oil Pressure Regulation Valve -N428- Component location, refer to «OIL PRESSURE REGULATION VALVE -N428»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) Removing and installing, refer to «Removal and Installation»(/audi/a5/i-2007-2011/remont/lubrication-system/#32l-lubrication-engine-codes-cala-coupe-as-of-122008)
9. Ignition Coils, Cylinder Bank 2 Ignition coil 4 with power output stage -N292- Ignition coil 5 with power output stage -N323- Ignition coil 6 with power output stage -N324- Removing and installing, refer to «IGNITION COILS»(ref-520191-S17023316332012123100000)
10. Camshaft Adjuster Actuators Cam adjustment actuator 7 -F372- Cam adjustment actuator 8 -F373- Cam adjustment actuator 9 -F374- Cam adjustment actuator 10 -F375- Cam adjustment actuator 11 -F376- Cam adjustment actuator 12 -F377- Component location, refer to «LOCATION ON LEFT CYLINDER BANK 2»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe)
11. Camshaft Position Sensor 2 -G163- 9 Nm Replace O-rings Component location, refer to «LOCATION ON LEFT CYLINDER BANK 2»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) Removing and installing, refer to «CAMSHAFT POSITION SENSOR»(ref-520191-S36668883822012123100000)
12. Intake Manifold Tuning Valve Position Sensor -G513- Component location, refer to «COMPONENT LOCATION FRONT ON ENGINE»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe)
13. Fuel Injector, Cylinder Bank 2 Cylinder 4 fuel injector -N33
14. Fuel Pressure Sensor -G247- Component location, refer to «COMPONENT LOCATION VIEW FROM INSIDE FROM THE LEFT CYLINDER BANK 2»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe)
15. Knock Sensor 2 -G66- Component location, refer to «COMPONENT LOCATION VIEW FROM INSIDE FROM THE LEFT CYLINDER BANK 2»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) Connector location, refer to «ELECTRICAL CONNECTORS»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) Removing and installing, refer to «KNOCK SENSORS»(ref-520191-S02091926662012123100000)
16. Fuel Injectors, Cylinder Bank 2 Cylinder 5 fuel injector -N83- Cylinder 6 fuel injector -N84- Component location, refer to «COMPONENT LOCATION VIEW FROM INSIDE FROM THE LEFT CYLINDER BANK 2»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) Removing and installing, refer to «FUEL INJECTORS»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe__fuel-injectors)

1. Engine Speed Sensor -G28- 9 Nm Component location, refer to «LOCATION ENGINE SPEED SENSOR -G28»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) Removing and installing, refer to «ENGINE SPEED SENSOR»(ref-520191-S40632402372012123100000)
2. Fuel Pump Control Module -J538- Component location, refer to «FUEL PUMP CONTROL MODULE -J538- -1»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) Removing and installing, refer to «Removal and Installation»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012)
3. Accelerator Pedal Position Sensor -G79- /Accelerator Pedal Position Sensor 2 -G185- In footwell on accelerator pedal (both sensors are integrated into one housing) Component location (Scheme 182) Removing and installing, refer to «Removal and Installation»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012)
4. Brake Light Switch -F- /Brake Pedal Switch -F47- In footwell at brake pedal Removing and installing, refer to «Removal and Installation»(/audi/a5/i-2007-2011/remont/anti-locktraction-control/#anti-lock-brake-system-coupe) Component location, refer to «CLUTCH POSITION SENSOR -G476- -2»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe)
5. Clutch Position Sensor -G476- Only for vehicles with manual transmission Component location, refer to «CLUTCH POSITION SENSOR -G476- -2»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe)
6. Oil Pressure Switch -F22- Component location, refer to «OIL PRESSURE SWITCH -F22- -ARROW»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) Checking, removing and installing, refer to «Removal and Installation»(/audi/a5/i-2007-2011/remont/lubrication-system/#32l-lubrication-engine-codes-cala-coupe-as-of-122008)
7. Reduced Oil Pressure Switch -F378- Component location, refer to «REDUCED OIL PRESSURE SWITCH -F378»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe)
8. Relay and Fuse Carrier in left E-box Plenum Chamber Locations, refer to the appropriate SYSTEM WIRING DIAGRAMS information

Scheme 180

1. In the left E-box in the engine compartment.

Scheme 181

Removing and installing, refer to Removal and Installation

Scheme 182

2 - Electrical harness connector

Scheme 183

Integrated functionalities: clutch pedal starter interlock switch -F194- and clutch pedal switch -F36

1 - Brake light switch -F- and brake pedal switch -F47

Scheme 184

1. Camshaft position sensor 3 -G300
2. Exhaust camshaft adjustment valve 1 -N318
3. Camshaft adjustment valve 1 -N205
4. Cam adjustment actuator 6 -F371
5. Cam adjustment actuator 5 -F370
6. Cam adjustment actuator 4 -F369
7. Cam adjustment actuator 3 -F368
8. Cam adjustment actuator 2 -F367
9. Cam adjustment actuator 1 -F366
10. Camshaft position sensor -G40

Scheme 185

1. Camshaft position sensor 2 -G163
2. Cam adjustment actuator 7 -F372
3. Cam adjustment actuator 8 -F373
4. Cam adjustment actuator 9 -F374
5. Cam adjustment actuator 10 -F375
6. Cam adjustment actuator 11 -F376
7. Cam adjustment actuator 12 -F377
8. Camshaft Adjustment Valve 2 -N208
9. Exhaust camshaft adjustment valve 2 -N319
10. Camshaft position sensor 4 -G301

Scheme 186

1. Cylinder 1 Fuel Injector -N30
2. Cylinder 2 Fuel Injector -N31
3. Cylinder 3 Fuel Injector -N32
4. Knock Sensor 1 -G61

Scheme 187

1. Cylinder 6 Fuel Injector -N84
2. Cylinder 5 Fuel Injector -N83
3. Cylinder 4 Fuel Injector -N33
4. Fuel Pressure Sensor -G247
5. Knock Sensor 2 -G66

Scheme 188

Scheme 189

Scheme 190

Scheme 191

1. Engine Coolant Temperature Sensor -G62
2. Intake Manifold Tuning Valve -N156
3. Intake Manifold Tuning Valve Position Sensor -G513

Scheme 192

1. Low Fuel Pressure Sensor -G410
2. Fuel Metering Valve -N290

Scheme 193

1. Bolted in the transmission from below

Scheme 194

1 - Knock Sensor 2 -G66

2 - Fuel injectors, cylinder bank 2 and from the fuel pressure sensor -G247

Scheme 195

1 - Throttle valve control module -J338

2 - EVAP canister purge regulator valve 1 -N80

3 - Climatronic refrigerant shut-off valve -N422- (only on vehicles without an auxiliary heater)

4 - Intake Air Temperature Sensor -G42- /Manifold Absolute Pressure Sensor -G71

Scheme 196

1 - EVAP canister purge regulator valve 1 -N80

2 - Secondary air injection solenoid valve -N112

3 - Intake Air Temperature Sensor -G42- /Manifold Absolute Pressure Sensor -G71

4 - Climatronic refrigerant shut-off valve -N422- (only on vehicles without an auxiliary heater)

5 - Secondary Air Injection Solenoid Valve 2 -N320

6 - Throttle valve control module -J338

Scheme 197

1 - Fuel injectors, Cylinder bank 1

2 - Throttle valve control module -J338

3 - Knock Sensor 1 -G61

4 - Heated oxygen sensor -G39

5 - Oxygen sensor after three way catalytic converter -G130

Scheme 198

1 - Heated oxygen sensor -G39

2 - Oxygen sensor after three way catalytic converter -G130

Scheme 199

1 - Oxygen sensor 2 after catalytic converter -G131

2 - Heated oxygen sensor 2 -G108

3 - Fuel injectors, cylinder bank 2 and from the fuel pressure sensor -G247

4 - Knock sensor 2 -G66

Scheme 200

1 - Heated oxygen sensor 2 -G108

2 - Oxygen sensor 2 after catalytic converter -G131

Scheme 201

1. Hose Clamp
2. Air Guide Hose To throttle valve control module -J338- Pay attention to the marking when installing (the arrow faces toward the throttle valve control module bolt)
3. Air Filter Always use an original air filter Maintenance interval. Refer to «03 MAINTENANCE, DIAGNOSIS»(/audi/a5/i-2007-2011/remont/procedures/#how-to-diagnosis-the-maintenance-maintenance-procedures-coupe) Removing and installing, refer to «AIR FILTER»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe__air-filter) Clean snow screen also (if present)
4. Air Duct Clipped into upper section of air filter housing Clean air duct of dirt and leaves
5. Air Duct Clean air duct of dirt and leaves
6. Air Duct To lock carrier Clean air duct of dirt and leaves
7. Rubber Grommet
8. Water Drain Hose Clean water drain hose of dirt and leaves (important)
9. Water Drain Hose Guide
10. Warm Air Intake (only installed in countries with hot climates) Slide the warm air intake into the air filter as far as the stop and then turn it clockwise until it engages.
11. Air Filter Housing Lower Section Clean the air filter housing lower section of salt residue, dirt and leaves Check water drain for dirt, clean if necessary (important)
12. Fastener for the Air Filter Housing Lower Section
13. Secondary Air Injection Pump Intake Hose Not equipped on all vehicles
14. Intake Air Switch-Over Valve -N335- Not equipped on all vehicles The valve is installed but is not functional
15. Bolt For the intake air switch-over valve -N335
16. Bolt
17. Air Filter Housing Upper Section Clean the air filter housing upper section of salt residue, dirt and leaves
18. Bolt For securing the air filter element

Scheme 202

1. Vacuum Hose
2. Intake Manifold Tuning Valve -N156
3. Bolt For intake manifold tuning valve position motor -G513- 2.5 Nm
4. Bolt 2.5 Nm
5. Actuator for Intake Manifold Change-Over Installed location of tooth segments for variable intake manifold, refer to «INSTALLED LOCATION OF TOOTH SEGMENTS FOR VARIABLE INTAKE MANIFOLD»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) As replacement part together with -26
6. Seal Replace if damaged Lift out with screwdriver to replace Press in by hand
7. Ball pin 2.5 Nm
8. Intake Manifold Upper Section Removing and installing, refer to «INTAKE MANIFOLD, UPPER SECTION»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe)
9. Seal Replace
10. Throttle Valve Control Module -J338
11. Bracket
12. Bolt 6 Nm
13. EVAP Canister Purge Regulator Valve 1 -N80
14. Hose
15. Bolt 3 Nm
16. Intake Air Temperature Sensor -G42- /Manifold Absolute Pressure Sensor -G71
17. O-ring Replace
18. Bolt 2.5 Nm
19. Hose for Crankcase Ventilation
20. O-ring Replace
21. Bolt 8 Nm
22. Washer
23. Sleeve
24. Seals Replace
25. Seal Replace if damaged Lift out with screwdriver to replace Press in by hand
26. Lever with Tooth Segment For variable intake manifold Installed location of tooth segments, refer to «INSTALLED LOCATION OF TOOTH SEGMENTS FOR VARIABLE INTAKE MANIFOLD»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe) As replacement part together with -5
27. Seal Replace if damaged Lift out with screwdriver to replace Press in by hand
28. Vacuum Hose

Scheme 203

1. The lower edges of the toothed segments must align with one another -arrow-.

Scheme 204

1. Intake Manifold Lower Section Left and right, removing and installing, refer to «INTAKE MANIFOLD, LOWER SECTION, WITH FUEL RAIL»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe__intake-manifold-lower-section-with-fuel)
2. Sleeve
3. Fuel Pressure Sensor -G247- 20 Nm
4. Bracket
5. Bolt 9 Nm
6. High-Pressure Line WARNING: There is a risk of injury because the fuel is under very high pressure. Before opening high pressure area of the fuel injection system, fuel pressure must be relieved to residual pressure. Reduce the fuel pressure in the high pressure area, refer to «BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe__before-opening-high-pressure-fuel-injection) . Do not change bend shape Never bend the bracket from the fuel line. If the bracket is bent, or if the fuel line is being replaced, then the bracket must be replaced. Tightening, refer to «HIGH PRESSURE LINE, INSTALLING»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe__high-pressure-line-installing)
7. Bolt 9 Nm
8. Threaded Support 40 Nm
9. Stud Bolt
10. Nut 9 Nm
11. Fuel Rail Retaining Bracket
12. Bolt 2.5 Nm
13. Bolt 9 Nm
14. Sleeve
15. Fuel Rail
16. Seals Replace
17. Support Ring Make sure it is seated properly The fuel rail wields force via the support ring to hold the fuel injector tightly in the cylinder head.
18. O-ring Replace Coat with clean engine oil
19. Spacer Ring Replace if damaged
20. Combustion Chamber Seal Replacing, refer to «FUEL INJECTORS»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe__fuel-injectors) .
21. Radial Adjustment Replace if damaged Clip with support ring, refer to item 17
22. Fuel Injector Removing and installing, refer to «FUEL INJECTORS»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe__fuel-injectors)

HIGH PRESSURE LINE, INSTALLING

First tighten the high pressure line union nut by hand.

Make sure the high pressure line does not have tension.

Use the torque wrench V.A.G 1331 with the 17 mm open end wrench socket V.A.G 1331/2 to tighten the high pressure line on the fuel rail.

Scheme 205

1. Tightening specification: union nut on the high pressure lines, 27 Nm

Scheme 206

1. Low Fuel Pressure Sensor -G410- 15 Nm
2. Seal Replace
3. Bolt 9 Nm
4. High Pressure Pump With fuel metering valve -N290- Counterhold the connecting pieces when loosening and tightening fuel lines Tighten fuel line connecting pieces before installing fuel lines Removing and installing, refer to «HIGH PRESSURE PUMP»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe__high-pressure-pump) Do not disassemble
5. Threaded Support 27 Nm
6. Hose Clamp Replace; must be appropriate for the model type
7. Fuel Supply Hose Low pressure side
8. High Pressure Fuel Line WARNING: There is a risk of injury because the fuel is under very high pressure. Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure. Reduce the fuel pressure in the high pressure area, refer to «BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe__before-opening-high-pressure-fuel-injection) . Counter hold to loosen and tighten union nut on high pressure pump connecting pieces Tighten connecting pieces on high pressure pump before installing Installing, refer to «HIGH PRESSURE LINE, INSTALLING»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe)
9. Gasket Replace
10. Bolt 9 Nm
11. Camshaft Position Sensor -G40
12. Bolt 9 Nm
13. O-ring Replace Lubricate O-rings with clean engine oil before installing
14. Housing
15. Roller Tappet Lubricate O-rings with clean engine oil before installing
16. O-ring Replace Lubricate O-rings with clean engine oil before installing

Scheme 207

Tighten the bolts -arrows- on the protective plate -1-.

1. Tightening specifications: 9 Nm

First tighten the high pressure line union nut by hand.

Make sure the high pressure line does not have tension.

To tighten the high pressure line on the high pressure pump, use the torque wrench V.A.G 1331 with the ratchet V.A.G 1331/1 and 14 mm socket 3150.

Scheme 208

1. Tightening specification: union nut on the high pressure line, 25 Nm

OXYGEN SENSORS ASSEMBLY OVERVIEW

1 - Fuel injectors, cylinder bank 1

2 - Knock sensor 1 -G61

4 - Heated oxygen sensor -G39

5 - Oxygen sensor after three way catalytic converter -G130

1 - Oxygen sensor 2 after catalytic converter -G131

2 - Heated oxygen sensor 2 -G108

3 - Fuel injectors, cylinder bank 2 and from the fuel pressure sensor -G247

4 - Knock sensor 2 -G66

1 - Heated oxygen sensor -G39

2 - Oxygen sensor after three way catalytic converter -G130

Heated oxygen sensor -G39-, removing and installing. Refer to HEATED OXYGEN SENSOR IN FRONT OF RIGHT CATALYTIC CONVERTER

Oxygen sensor after three way catalytic converter -G130-, removing and installing. Refer to OXYGEN SENSOR BEHIND THREE WAY CATALYTIC CONVERTER

1. Tightening specifications: 55 Nm

1 - Heated oxygen sensor 2 -G108

2 - Oxygen sensor 2 after catalytic converter -G131

Heated oxygen sensor 2 -G108-, removing and installing. Refer to HEATED OXYGEN SENSOR 2 .

Oxygen sensor 2 after catalytic converter -G131-, removing and installing. Refer to OXYGEN SENSOR 2 BEHIND THREE WAY CATALYTIC CONVERTER .

1. Tightening specifications: 55 Nm

TECHNICAL DATA

FASTENER TIGHTENING SPECIFICATIONS

HIGH PRESSURE LINE PROTECTIVE PLATE, TIGHTENING SPECIFICATIONS

Tighten the bolts -arrows- on the protective plate -1-.

1. Tightening specifications: 9 Nm

FUEL SYSTEM, PERFORMING LEAK TEST

Proceed as follows

Let the engine run a few minutes at a moderate speed.

Switch off ignition.

Check the entire fuel system for leaks.

If there are leaks in spite of correct tightening specifications, the corresponding component must be replaced.

Then perform a road test and depress the accelerator pedal all the way at least one time.

Then check the high pressure area again for leaks.

VACUUM SYSTEM, CHECKING

Special tools and workshop equipment required

1. Hand Vacuum Pump VAS 6213

Procedure

Check all vacuum lines in the vacuum system for

1. Cracks
2. Damage caused by animals
3. Crimps
4. Leaks and leakage

Check the vacuum line leading to and from the solenoid valve.

If there is a fault, check the vacuum lines for the named component, but also all the vacuum lines to the other components.

If using the VAS 6213 does not produce any pressure or if the pressure drops again right away, then check the hand vacuum pump and the connection hoses for leaks.

FUEL PRESSURE AND RESIDUAL PRESSURE BEFORE HIGH PRESSURE PUMP, CHECKING

Special tools and workshop equipment required

1. Fuel Inj. Pressure Gauge-CIS V.A.G 1318
2. Pressure Gauge Adapter V.A.G 1318/10-12
3. Connector Test Set V.A.G 1594C
4. Remote Control V.A.G 1348/3A with Adapter Cable V.A.G 1348/3-3
5. Measuring container, fuel-resistant
6. Protective gloves

FUEL PRESSURE, CHECKING

1. Battery voltage at least 12.5 Volts.
2. Fuel filter OK.
3. Fuel tank at least 1 / 4 filled.
4. Fuel pump control module -J538- OK.
5. Ignition switched off.

Remove rear seat bench. Refer to Removal and Installation .

Remove the locking flange cover -arrows-.

Scheme 209

Disconnect electrical harness connector -1- at locking flange.

Scheme 210

Note. Ignore -2-.

Connect the V.A.G 1348/3A with V.A.G 1348/3-3 with an adapter cable from the V.A.G 1594C at terminal -1-.

Using insulating tape, tape over the second terminal on the V.A.G 1348/3-3 -arrow- to prevent a short circuit.

Scheme 211

Connect terminal -5- to the vehicle ground using a jumper cable from the V.A.G 1594C.

Connect the V.A.G 1348/3A to item -A- in the terminal box in the plenum chamber (battery positive). For safety reasons, install a fuse (10 A) in the wiring connection.

Route V.A.G 1348/3A switch forward in engine compartment.

Remove the seal -arrow-.

Scheme 212

Unclip the plenum chamber cover -2- and remove it.

Note. Ignore -1 and 3-.

Release the retainer -arrow A- and open the cover -arrow B-.

Scheme 213

Connect the alligator clip to the battery jump start terminal -U6- -A- in the terminal 30 wire junction 2 -TV22- in the plenum chamber.

Remove fuel filler cap from fuel filler tube.

Remove the front engine cover.

Remove the fuel supply line -arrow- from the high pressure pump.

Scheme 214

Connect the V.A.G 1318 to the fuel supply line using an adapter.

Scheme 215

Connect an assisting hose -arrow- to pressure gauge and hold it in a measuring container.

Open shut-off valve of pressure gauge.

1. The lever points in the direction of flow.

Bleed fuel system by pressing remote control briefly.

Close shut-off valve of pressure gauge.

Scheme 216

1. Lever stands perpendicular to direction of flow -arrow-.

Hold the switch of the remote control until no more pressure increase is observed on the fuel pressure gauge.

1. Specified value: approximately 5.5 bar (4.5 to 6.5 bar) positive pressure.

If the specification is not obtained

Check delivery quantity of Fuel Pump (FP). Refer to Diagnosis and Testing .

RESIDUAL PRESSURE, CHECKING

Check for leaks and residual pressure by observing pressure drop on pressure gauge.

1. After 10 minutes there must be a residual pressure of at least 3 bar.

If the residual pressure drops below 3 bar

1. Check connection between fuel pressure gauge and fuel line for leaks.
2. Check pressure gauge for leaks.
3. Check fuel lines and their connections for leaks.
4. Check delivery quantity of Fuel Pump (FP). Refer to «Diagnosis and Testing»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012) .
5. Replace fuel filter with integrated fuel pressure regulator. Refer to «Removal and Installation»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012) .
6. Fuel pump check-valve is faulty. Refer to «Diagnosis and Testing»(/audi/a5/i-2007-2011/remont/fuel-system/#fuel-supply-system-engine-codes-caeb-cala-caua-coupe-as-of-052012) .

Assembly is in reverse order of removal, note the following

Switch off ignition.

Note. Before removing pressure gauge, release fuel pressure by opening shut-off valve. Hold a container under the connection.

Connect the fuel supply line -arrow- to the high pressure pump.

Note. Check fuel system for leaks.

WIRING AND COMPONENTS, CHECKING WITH TEST BOX VAG 1598/42

Special tools and workshop equipment required

1. Adapter Cable - V.A.G 1598/39-1
2. Adapter Cable - V.A.G 1598/39-2
3. Test Box - V.A.G 1598/42

Note. The test box is designed with 105 pins. The connection cable can be separated from the test box. This means that as new engine control module (ECM) connectors are introduced in the future, only a new cable must be designed and no longer the entire test box. The smaller of the two connectors on the ECM is assigned with terminals 1 to 60. The larger of the two connectors is assigned with terminals 1 to 94. If a wiring connection to the ECM is to be tested, use the wiring diagrams to determine through which connector the electrical wiring connection leads to the ECM. Lead the electrical wiring connector to the 60-pin connected, then connect the smaller of the two connectors V.A.G 1598/39-1 to the input A on the test box V.A.G 1598/42. If an electrical wiring connection leads to the 94-pin connector according to wiring diagram, connect the larger of the two connectors V.A.G 1598/39-2 as follows. The connector designated with an A must be connected to input A of the V.A.G 1598/42 and the connector B must be connected to input B of the V.A.G 1598/42. The V.A.G 1598/42 is designed so that it can be connected simultaneously to the engine control module harness and the engine control module itself. This is advantageous because electronic engine control remains fully functional (for example measurement of signals with engine running) when the test box is attached. The procedures will indicate whether the engine control module is to remain connected to the test box or not. Always use V.A.G 1594 C to connect measuring equipment (for example voltage tester V.A.G 1527 B, portable multimeter V.A.G 1526 C, etc.)

Remove engine control module -J623-. Refer to ENGINE CONTROL MODULE .

Connect V.A.G 1598/42 to wiring harness connector. Ground (GND) clip at test box must be clipped to battery minus. The procedures will indicate whether the engine control module is to be connected to the test box.

Perform test as described in relevant repair sequences.

INSTALLING ENGINE CONTROL MODULE

Install in reverse order of removal.

The engine control module must be equipped with the metal retainer again.

New shear bolts must always be used.

Clean the threaded holes of residue and locking compound for the new shear bolts. Cleaning can be performed with a thread cutter (tap).

Check the DTC memory and, if necessary, erase it. After DTC memory is erased, a readiness code must be generated for the engine control module using the guided functions operating mode, see vehicle diagnosis and service system VAS 5052.

Note. When ending guided fault finding, the tester attempts to erase the DTC memory of all control modules. If this is not successful, the remaining DTCs stored in memory must be corrected until all DTCs can be erased.

AIR FILTER

Removing

Remove the air guide hose from the air filter housing by opening the clips -arrows-.

Scheme 217

Remove the bolts -arrows- from the upper section of the air filter housing and remove the upper section of the housing upward.

Scheme 218

Note. Always use an original air filter. Use a lubricant (silicone -free) for installing the air duct hose. Secure all hose connections using hose clamps of series-production status.

Check the water drain hose -arrow- in the lower section of the air filter for dirt and contamination (clean if necessary).

Scheme 219

Clean air filter housing (upper and lower sections) of salt residue, dirt or leaves (use vacuum cleaner if necessary).

Check the intake channels up to the air filter for dirt.

When installing the air filter element, make sure it is centered in the mount in the lower section of the air filter housing.

Assemble the new air filter element with the upper section of the air filter housing.

Scheme 220

The tab on the air filter element -1- must align with the tab on the air filter housing -2-.

Scheme 221

Place upper section of air filter housing on to lower section or air filter housing carefully and without using excessive force.

Note. Check again before tightening if the upper section of the air filter housing is in the groove on the lower section (leaks).

Then bolt the upper section of the air filter housing to the lower section.

Make sure the air guide hoses are secure.

Further installation is in reverse order.

REMOVING

Remove the air guide hose from the air filter housing by opening the clips -arrows-.

Remove the bolts -arrows- from the upper section of the air filter housing and remove the upper section of the housing upward.

Disconnect the vacuum hose -1- on the intake air switch-over valve -N335- -2-.

Release the fastener from the lower section of the air filter housing (press the rubber in at the left and right pull upward).

Note. Do not use any lubricant when installing the fastener.

Disconnect the air guide hose -1- to the secondary air injection pump.

Scheme 222

Note. Item 1 is not installed on all vehicles (EU 5 only). The electrical connector on the intake air switch-over valve is not installed on all vehicles.

Remove the lower section of the air filter housing.

INSTALLING

Note. Always use an original air filter. Use a lubricant (silicone -free) for installing the intake hose. Secure all hose connections using hose clamps of series-production status.

If a warm air intake is installed (only for countries with warm climates), make sure the air intake connectors are engaged correctly -arrows- (check markings).

Scheme 223

Check the water drain hose -arrow- in the lower section of the air filter for dirt and contamination (clean if necessary).

Clean air filter housing (upper and lower sections) of salt residue, dirt or leaves (use vacuum cleaner if necessary).

Check the intake channels up to the air filter for dirt.

Connect the electrical connector on the intake air switch-over valve (if applicable).

Connect the air guide hose -1- (if applicable).

Install the lower section of the air filter housing.

Note. Route the water drain hose straight down, do not bend it.

Slide the vacuum hose -1- onto the intake air switch-over valve connection.

The tab on the air filter element -1- must align with the tab on the air filter housing -2-.

Place upper section of air filter housing on to lower section or air filter housing carefully and without using excessive force.

Note. Check again before tightening if the upper section of the air filter housing is in the groove on the lower section (leaks).

Then bolt the upper section of the air filter housing to the lower section.

Make sure the air guide hoses are secure.

Further installation is in reverse order.

Note. During installation, all cable ties must be installed at the same location.

Remove the front and rear engine covers.

Free up the hose connection -1- to the EVAP canister.

Remove the vacuum hose -2- from the air guide hose connection.

Remove the air guide hose by loosening the hose clamp -3- and opening the clips -arrows-.

Note. Ignore -4-.

Disconnect vacuum hose -2-.

Scheme 224

Note. Disregard the -arrow-.

1 - EVAP canister purge regulator valve 1 -N80

2 - Secondary air injection solenoid valve -N112- (on Emissions Standard ULEV 2 vehicles only)

3 - intake air temperature sensor -G42- /manifold absolute pressure sensor -G71

4 - Climatronic refrigerant shut-off valve -N422- (only on vehicles without an auxiliary heater)

5 - Secondary air injection solenoid valve 2 -N320- (on Emissions Standard ULEV 2 vehicles only)

6 - Throttle valve control module -J338

Remove the EVAP canister purge regulator valve 1 from the bracket and lay it aside with the hose connected.

Disconnect the connectors on the front of the intake manifold.

1. Intake manifold tuning valve -N156
2. Intake manifold tuning valve position sensor -G513

Remove the vacuum hose -arrow-.

Scheme 225

Disconnect vacuum hose -arrow- at leak detection pump.

Scheme 226

Free up the vacuum hose -arrow-.

Scheme 227

Free up the wiring harness.

Remove bolt -3-.

Press the retaining tab -2- up slightly and disconnect the crankcase ventilation hose from the intake manifold.

Remove the bolts -arrows- and the upper section of the intake manifold.

Scheme 228

Note. Plug the intake ports of the cylinder head with clean rags.

Installation is in reverse order of removal, note the following

1. Tightening specifications, refer to «INTAKE MANIFOLD, UPPER SECTION ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe)

Note. Replace seals and O-rings. During installation, all cable ties must be installed at the same location. Secure all hose connections using hose clamps appropriate for the model type.

INTAKE MANIFOLD, LOWER SECTION, WITH FUEL RAIL

Special tools and workshop equipment required

1. Torque Wrench V.A.G 1331
2. Ring Spanner Insert V.A.G 1331/2

Note. The following removal and installation procedure is for the left lower section of the intake manifold. The procedure for the other side is identical.

Remove the upper section of the intake manifold. Refer to INTAKE MANIFOLD, UPPER SECTION .

Disconnect the electrical connector on the fuel pressure sensor -G247- -2-.

Scheme 229

Remove the union nut -1-.

Remove the bolts and nuts -arrows- and remove the lower section of the intake manifold with the fuel rail.

Note. Plug the intake ports of the cylinder head with clean rags.

Installation is in reverse order of removal, note the following

Note. Replace seals and O-rings. Lubricate the fuel injector O-rings lightly with clean engine oil.

Press the lower section of the intake manifold with the fuel rail evenly onto the fuel injectors.

Tighten the bolts and nut -arrows- on the lower section of the intake manifold diagonally in stages.

1. Tightening specification, refer to «INTAKE MANIFOLD, LOWER SECTION, WITH FUEL RAIL ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe)

Disconnect the electrical connector -2- on the fuel pressure sensor.

Install the high pressure line -1- on the fuel rail. Refer to HIGH PRESSURE LINES .

Note. Check fuel system for leaks.

Remove the upper section of the intake manifold. Refer to INTAKE MANIFOLD, UPPER SECTION .

Disconnect the electronic connector from the fuel pressure sensor -G247- -4-.

Remove the fuel pressure sensor -4-.

Installation is in reverse order.

1. Tightening specification, refer to «INTAKE MANIFOLD, LOWER SECTION, WITH FUEL RAIL ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe)

Install the upper section of the intake manifold, refer to INTAKE MANIFOLD, UPPER SECTION .

HIGH PRESSURE PUMP

Special tools and workshop equipment required

1. Torque Wrench V.A.G 1331
2. Ratchet, Reversible V.A.G 1331/1
3. Socket 14 mm 3150

Note. The removal and installation of the high-pressure fuel pump can only be performed on a cold engine. When installing the high-pressure fuel pump, make sure that no dirt enters the fuel system. Catch escaping fuel with a rag. The O-ring must always be replaced. High-pressure fuel lines must always be fastened free of tension.

Remove the lower section of the air filter housing. Refer to AIR FILTER HOUSING, LOWER SECTION .

Remove the bolts -arrows- and the protective plate -1-.

Disconnect electrical connectors -1- and -6-.

Scheme 230

Disconnect the fuel supply line -2- and remove the threaded connection -5-.

Remove the bolts -3- and -4- on the retaining clamps.

Remove the bolts -arrows- and pry the end cover up carefully.

Note. Do not change the angles of the fuel lines. Never bend any of the fuel line mounting clamps. If a mounting clamp was bent, or if the fuel line is being replaced, then the mounting clamps must also be replaced.

Carefully remove high pressure pump.

Remove the roller tappet -1- from the housing.

Scheme 231

Installation is in reverse order of removal, note the following

Note. High pressure line connections must not show any signs of damage. Do not change the angles of the fuel lines. Never bend any of the fuel line mounting clamps. If a mounting clamp was bent, or if the fuel line is being replaced, then the mounting clamps must also be replaced.

Replace the O-ring for the high-pressure pump.

Check the plunger -1- for damage and replace it if necessary.

Coat the plunger with oil and insert it with the tab -arrow A- in the guide -arrow B-.

Note. To insert the high pressure pump, the roller tappet must be at its lowest point.

Rotate the crankshaft in the direction of engine rotation at the vibration damper bolt while pressing the roller tappet into the cylinder head until it reaches the deepest point.

Only lift the high pressure line slightly to insert the high pressure pump.

Install the high pressure pump into the housing.

Tighten the bolts -arrows- hand-tight until they contact the flange.

Tighten the bolts diagonally (approximately 1 turn until they touch the high pressure pump) with the necessary tightening specification.

Note. Tightening the bolts on one side at time will damage the pump.

1. Tightening specification, refer to «HIGH PRESSURE PUMP ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe)

Tighten the union nut -5- on the fuel return line hand-tight. Align so it is free of stress.

Install the fuel supply hose -2-.

Tighten the bolts -3- and -4- on the hose clamps.

Connect the connectors -1- and -6-.

Tighten the high pressure line to the tightening specification, refer to HIGH PRESSURE LINE, INSTALLING .

Install the shield -1-.

Remove the air filter housing lower section. Refer to AIR FILTER HOUSING, LOWER SECTION .

Note. Check fuel system for leaks.

FUEL INJECTORS

Special tools and workshop equipment required

1. Tool Set T10133

Note. The puller T10133/2 was changed and is now called puller T10133/2-A. If the new tool is not available, the old one can be modified.

Modify the puller T10133/2 to create the puller T10133/2-A.

Special tools and workshop equipment required

1. Round file approximately 6 mm

File the semicircle as shown in the illustration. The semicircle allows the tool to slide farther onto the fuel injector, thus providing the tool with a larger contact surface.

Mark the modified tool with an A at the end of the tool number.

Scheme 232

Scheme 233

1. Radial adjustment - Replace if damaged
2. Combustion chamber seal (Teflon seal) - replace, the seal must not be greased or be handled with any other lubricant during installation
3. Groove on fuel injector
4. Spacer ring - Replace if damaged
5. O-ring - replace, lightly coat with clean engine oil during installation
6. Support ring - fuel rail wields force via the support ring to hold the fuel injector tightly in the cylinder head

Remove the upper section of the intake manifold. Refer to INTAKE MANIFOLD, UPPER SECTION .

Remove the affected intake manifold lower section. Refer to INTAKE MANIFOLD, LOWER SECTION, WITH FUEL RAIL .

If the fuel injectors cannot be pulled out of the cylinder head by hand, proceed as follows

Using a screwdriver, bend the retaining tabs -1- of the radial adjustment aside -arrow- and pull the support ring -2- from the fuel injector.

Scheme 234

Guide the T10133/2A in the groove on the fuel injector.

Scheme 235

Then position the trim removal wedge T10133/16 and remove the fuel injector by loosening the bolt -1-.

Note. When setting the puller in place, the radial adjustment can be destroyed, because the retaining tabs break.

Carefully remove the old combustion chamber seal -arrow-, thereby cutting seal open with a knife or spreading seal open with a small screwdriver and pulling it forward and off.

Scheme 236

Make sure that the groove of the fuel injector does not become damaged. If the groove is damage, the fuel injector must be replaced.

Note. Replace the combustion chamber seals and O-rings. Replace the spacer ring and radial adjuster if damaged. Lightly coat fuel injector O-rings with clean engine oil. Install the cylinder at same cylinder.

Clip the radial adjustment -1- to the support ring -2-.

Scheme 237

When re-installing a fuel injector, use a clean cloth to clean combustion residue from the groove for combustion chamber seal and the shaft of the fuel injector.

Place assembly cone T10133/5 with new combustion chamber seal -1- on fuel injector -2-.

Scheme 238

Slide combustion chamber seal as far possible onto assembly cone T10133/5 using assembly sleeve T10133/6.

Scheme 239

Turn T10133/6 around and slide combustion chamber seal into groove.

Note. When pushing the combustion chamber seal onto the fuel injector, the seal spreads open. Therefore after pushing it on, it must be tightened again in 2 steps, as follows.

Press the sizing sleeve T10133/7 with a slight turning motion (approximately 180°) onto the fuel injector until it stops.

Pull the T10133/7 off again, turning it in the opposite direction.

Press the sizing sleeve T10133/8 with a slight turning motion (approximately 180°) onto the fuel injector until it stops.

Scheme 240

Pull the sizing sleeve T10133/8 off again, turning it in the opposite direction.

Coat the new O-ring with clean engine oil before installing.

Note. The combustion chamber seal must not be oiled.

FUEL INJECTORS, INSTALLING

Clean bore in cylinder head with nylon cylinder brush T10133/4.

Scheme 241

Slide fuel injector into the bore cylinder head as far as stop using assembly drift T10133/9.

Scheme 242

Note. The fuel injector must not be difficult to install. If necessary, wait as the combustion chamber seal continues to pull itself together.

Make sure fuel injectors are correctly positioned in cylinder head.

1. The electrical connection of the fuel injector must engage in the intended recess of the cylinder head.

The rest of the installation is in reverse order of removal, note the following

Install the lower section of the intake manifold. Refer to INTAKE MANIFOLD, LOWER SECTION, WITH FUEL RAIL .

Install the upper section of the intake manifold. Refer to INTAKE MANIFOLD, UPPER SECTION .

HIGH PRESSURE LINES

Special tools and workshop equipment required

1. Torque Wrench V.A.G 1331
2. Ring Spanner Insert V.A.G 1331/2

Note. Tighten the union nut on the fuel high pressure pump, see HIGH PRESSURE LINE, INSTALLING High pressure line connections must not show any signs of damage. Do not bend the high pressure lines to a different angle. Never bend any of the fuel line mounting clamps. If a mounting clamp was bent, or if the fuel line is being replaced, then the mounting clamps must also be replaced.

Coat the threads on the union nut with fuel.

Tighten the high pressure line union nuts by hand, making sure they are seated without tension.

Use the V.A.G 1331 with the open end V.A.G 1331/2 to tighten the high pressure line on the fuel rail.

1. Tightening specification: union nut on the high pressure lines, 25 Nm

Only install the retaining tabs after tightening the high pressure lines.

Check the fuel system for leaks.

HEATED OXYGEN SENSOR IN FRONT OF RIGHT CATALYTIC CONVERTER

Special tools and workshop equipment required

1. Ring Spanner 7-Piece Set 3337

Pull rear engine cover off -arrows-.

Scheme 243

Free up the fuel supply line -4- and hose connection -1- to the EVAP canister on the air filter housing and on the air guide tube.

Remove the vacuum hose -2- from the air guide hose.

Remove the air guide hose by loosening the hose clamp -3- and opening the clips -arrows-.

Remove the lower section of the air filter housing. Refer to AIR FILTER HOUSING, LOWER SECTION .

Disconnect the electrical connector -4- for the heated oxygen sensor -G39-.

Remove the heated oxygen sensor -1- using a tool from the 3337.

Note. The installation location is shown with the engine removed.

Installation is in reverse order of removal, note the following

1. Tightening specification, refer to «OXYGEN SENSORS ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe__oxygen-sensors-assembly-overview) .

Note. New oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body. For a used oxygen sensor, only coat threads with hot bolt paste. This paste must not come into contact with sensor slots. Electrical wire of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided. During installation, all cable ties must be installed at the same location.

OXYGEN SENSOR BEHIND THREE WAY CATALYTIC CONVERTER

Special tools and workshop equipment required

1. Ring Spanner 7-Piece Set 3337

Pull rear engine cover off -arrows-.

Free up the fuel supply line -4- and hose connection -1- to the EVAP canister on the air filter housing and on the air guide tube.

Remove the vacuum hose -2- from the air guide hose.

Remove the air guide hose by loosening the hose clamp -3- and opening the clips -arrows-.

Disconnect the electrical connector -5- for the oxygen sensor after three way catalytic converter -G130-.

Remove the oxygen sensor after three way catalytic converter -2- using a tool from the 3337.

Note. The installation location is shown with the engine removed.

Installation is in reverse order of removal, note the following

1. Tightening specification, refer to «OXYGEN SENSORS ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe__oxygen-sensors-assembly-overview)

Note. New oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body. For a used oxygen sensor, only coat threads with hot bolt paste. This paste must not come into contact with sensor slots. Electrical wire of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided. During installation, all cable ties must be installed at the same location.

HEATED OXYGEN SENSOR 2

Special tools and workshop equipment required

1. Ring Spanner 7-Piece Set 3337

Pull rear engine cover off -arrows-.

Remove the coolant reservoir -arrows-.

Scheme 244

Disconnect the electrical connector to the engine coolant level warning switch -F66- on the bottom of the coolant reservoir and lay the reservoir aside with the coolant hoses -1 and 2- and -3- attached.

Disconnect the electrical connector -2- for the heated oxygen sensor 2 -G108-.

Remove the heated oxygen sensor 2 -1- using a tool from the 3337.

Note. The installation location is shown with the engine removed.

Installation is in the reverse order of removal, note the following

1. Tightening specification, refer to «OXYGEN SENSORS ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe__oxygen-sensors-assembly-overview)

Note. New oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body. For a used oxygen sensor, only coat threads with hot bolt paste. This paste must not come into contact with sensor slots. Electrical wire of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided. During installation, all cable ties must be installed at the same location.

OXYGEN SENSOR 2 BEHIND THREE WAY CATALYTIC CONVERTER

Special tools and workshop equipment required

1. Ring Spanner 7-Piece Set 3337

Pull rear engine cover off -arrows-.

Remove the coolant reservoir -arrows-.

Disconnect the electrical connector to the engine coolant level warning switch -F66- on the bottom of the coolant reservoir and lay the reservoir aside with the coolant hoses -1 and 2- and -2- attached.

Disconnect the electrical connector -1- for the oxygen sensor 2 after catalytic converter -G131-.

Remove the oxygen sensor 2 after catalytic converter -2- using a tool from the 3337.

Note. The installation location is shown with the engine removed.

Installation is in reverse order of removal, note the following

1. Tightening specification, refer to «OXYGEN SENSORS ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe__oxygen-sensors-assembly-overview)

Note. New oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body. For a used oxygen sensor, only coat threads with hot bolt paste. This paste must not come into contact with sensor slots. Electrical wire of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided. During installation, all cable ties must be installed at the same location.

ENGINE CONTROL MODULE

Special tools and workshop equipment required

1. Hot Air Blower VAS 1978/14 with nozzle attachment from Wiring Harness Repair Kit VAS 1978
2. Small, commercially available locking pliers (vise grips)

Note. The Engine Control Module (ECM) -1- is bolted to a protective housing -5-. To make removing the shear bolts -4- for the retaining tabs -2- more difficult, the threads are coated with locking compound. To disconnect the connectors from the ECM (for example to connect the test box or to replace the ECM), the metal housing must be removed.

If the engine control module is replaced, in guided fault finding select replace engine control module to vehicle diagnosis, testing and information system VAS 5051B.

Turn the ignition and remove the ignition key.

Pull the plenum chamber cover rubber seal in front of the nut -1- slightly.

Scheme 245

Disengage the wiring harness -2- at the mounts -A-.

Remove nut -1-.

Remove the filler neck -3- with the filler tube from the washer fluid reservoir and the opening in the body.

Remove the bolts -arrows- and the cover from the E-box.

Scheme 246

Release the retainers -A arrows- and remove the engine control module -J623- -arrow B-.

To increase the difficulty with which the ECM connectors can be accessed, the ECM -1- is secured in a metal housing -5- with retaining tabs -2- and shear bolts -3 and 4-.

Scheme 247

The threads of the shear bolts -4- (that are not screwed into the ECM) are coated with a locking compound. For this reason, the threads must be heated with the heat gun to remove both bolts.

The threads of both shear bolts -3-, that are screwed into the ECM, are not coated with a locking compound. The threads in the ECM housing must not be heated and do not require to be heated (unintentional heating of the ECM).

Set the adjustment on the heat gun as shown in the illustration, with the temperature potentiometer -2- set to maximum heat and the two-stage airflow switch -3- set to level 3.

Scheme 248

Warm threads on connector-side shear bolts for approximately 25 to 30 seconds.

Scheme 249

Remove shear bolts with locking pliers (see direction of -arrow-).

Both shear bolts that are screwed into the ECM do not require heating to be removed. They can be removed without heat.

Scheme 250

Disconnect metal retainers from the ECM connectors.

Disengage connectors from ECM and then disconnect the connectors.

Remove old engine control module -J623- and install the engine control module.

Install in reverse order of removal.

After that, the engine control module must be equipped with the metal retainer.

Clean threaded holes for shear bolts of locking compound residue. Cleaning can be performed with a thread cutter (tap).

Always use new shear bolts.

1. Tightening specification: bolts for the E-box cover: 3.5 Nm

Perform the following step after installing a new engine control module

Activate the engine control module in the guided functions operating mode under replace engine control module on the vehicle diagnosis and service system VAS 5051B.

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 251

Scheme 252

Scheme 253

Scheme 254

Scheme 255

Scheme 256

Scheme 257

Scheme 258

Scheme 259

Scheme 260

1. Hand Vacuum Pump VAS 6213
2. Fuel Inj. Pressure Gauge-CIS V.A.G 1318
3. Pressure Gauge Adapter V.A.G 1318/10-12
4. Connector Test Set V.A.G 1594C
5. Remote Control V.A.G 1348/3A with Adapter Cable V.A.G 1348/3-3
6. Adapter Cable - V.A.G 1598/39-1
7. Adapter Cable - V.A.G 1598/39-2
8. Test Box - V.A.G 1598/42
9. Ring Spanner Insert V.A.G 1331/2
10. Torque Wrench V.A.G 1331
11. Ratchet, Reversible V.A.G 1331/1
12. Socket 14 mm 3150
13. Tool Set T10133
14. Ring Spanner 7-Piece Set 3337
15. Hot Air Blower VAS 1978/14 -1- with nozzle attachment -2- from Wiring Harness Repair Kit VAS 1978
16. Small, commercially available locking pliers -3- (vise grips)

See also:
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• 03 MAINTENANCE, DIAGNOSIS
• Removal and Installation
• BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM
• SAFETY PRECAUTIONS
• OXYGEN SENSORS LOCATION, CYLINDER BANK 1 (RIGHT)
• HEATED OXYGEN SENSOR IN FRONT OF RIGHT CATALYTIC CONVERTER
• OXYGEN SENSOR BEHIND THREE WAY CATALYTIC CONVERTER
• FUEL INJECTORS
• HIGH PRESSURE PUMP
• OXYGEN SENSOR 2 BEHIND THREE WAY CATALYTIC CONVERTER
• ENGINE CONTROL MODULE
• HEATED OXYGEN SENSOR 2
• AIR FILTER
• INTAKE MANIFOLD, LOWER SECTION, WITH FUEL RAIL
• HIGH PRESSURE LINE, INSTALLING
• HIGH PRESSURE LINES
• OXYGEN SENSORS ASSEMBLY OVERVIEW